Injection molded component and method of injection molding

ABSTRACT

An injection molded component includes a wall that has an inner wall surface and an outer wall surface. A sensor is molded into one of the inner wall surface and the outer wall surface. A channel is at least partially surrounding the sensor.

BACKGROUND

The application claims priority to U.S. Provisional Application No.62/472,816, which was filed on Mar. 17, 2017.

The disclosure relates to injection molded components. Moreparticularly, the disclosure relates to injection molded components,such as pallets or receptacles, having at least one sensor associatedwith the injection molded component.

When packing or transporting goods on pallets or in receptacles, it isbeneficial to the user to quickly and easily identify the goods storedon the pallet or in the receptacle, where the goods are being shipped,and/or the origin of the goods in addition to other information of theinjection molded component. A number of approaches have been used toprovide information to the user through the use of an indicatorassociated with the injection molded component. However, there is a needto improve the manufacturability of the injection molded components andthe operability of indicators associated with the injection moldedcomponents.

SUMMARY

In one exemplary embodiment, an injection molded component includes awall that has an inner wall surface and an outer wall surface. A sensoris molded into one of the inner wall surface and the outer wall surface.A channel is at least partially surrounding the sensor.

In another exemplary embodiment, a mold assembly includes a first moldwall that includes an inner surface. A wall extends from the innersurface to define a suction surface. At least one vacuum line is influid communication with the suction surface. A second mold wall opposesthe first mold wall and includes at least one extendable pin.

In another exemplary embodiment, a mold assembly includes a first moldwall that includes an inner surface. A portion of the inner surfacedefines a recessed surface. A first plurality of ribs extends across therecessed surface and includes a sensor contact surface that extends in aplane parallel to the recessed surface.

In another exemplary embodiment, a method of forming an injection moldedcomponent comprising the step of locating a sensor against a firstsurface of a mold. An edge of the sensor is surrounded by a wall thatextends from the first surface of the mold. An injectable material isinjected into the mold such that the injectable material travels over aninner surface of the sensor.

These and other features of the disclosed examples can be understoodfrom the following description and the accompanying drawings, which canbe briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example injection molded component, such as apallet, according to a non-limiting example of this disclosure.

FIG. 2 illustrates an enlarged view of a portion of the pallet of FIG. 1including an example tag.

FIG. 3 is an enlarged cross-sectional view taken along line 3-3 of FIG.2.

FIG. 4 is an enlarged cross-sectional view of the example tag takenalong line 4-4 of FIG. 2.

FIG. 5 is an enlarged cross-sectional view of another example tag.

FIG. 6 is an enlarged cross-sectional view of yet another example tag.

FIG. 7 is a cross-sectional view of a mold illustrating flow patterns.

FIG. 8 is a perspective view of a portion of the mold shown in FIG. 7.

FIG. 9 is a perspective view of an example suction surface of the moldshown in FIG. 7.

FIG. 10 illustrates a portion of an automation system for manipulatingthe example tag of FIG. 2.

FIG. 11 illustrates another portion of the automation system of FIG. 10.

FIG. 12 is a perspective view of another example suction surface of themold.

FIG. 13 is a perspective view of yet another example suction surface ofthe mold.

FIG. 14 is a perspective view of a portion of the pallet of FIG. 1including the example tag of FIG. 2 having a visual indicator.

FIG. 15 is a perspective view of a portion of another example mold.

FIG. 16 is a perspective view of the portion of the mold of FIG. 15 witha sensor.

FIG. 17 is a perspective view of the sensor of FIG. 16 molded into aportion of the pallet of FIG. 1.

FIG. 18 illustrates a cross-sectional view taken along line 18-18 ofFIG. 17.

DETAILED DESCRIPTION

FIG. 1 illustrates a pallet 10 according to one non-limiting example ofthis disclosure. The pallet 10 includes a top deck 12 and a bottom deck14. The top deck 12 and the bottom deck 14 are molded from a plasticmaterial such as polypropylene via an injection molding process, but ofcourse may be formed of various polymeric materials and processes toachieve the desired characteristics.

The top deck 12 includes an upper surface 16 for supporting goodsthereon. The top deck 12 mates with the bottom deck 14 at a mating line18. The bottom deck 14 includes multiple columns 20 that extenddownward. The columns 20 located along a perimeter of the pallet 10include a wall having an outer surface 22 that is generally flat. One ormore of the outer surfaces 22 include a RFID tag 30 molded into thecolumn 20. Although the RFID tag 30 is shown in one of the columns 20,the RFID tag 30 could also be located in the upper surface 16 or anothersuitable location on the pallet 10. Moreover, multiple RFID tags 30could be incorporated into the pallet 10. Additionally, the RFID tag 30could be used in another injection molded product, such as a crate oranother type of receptacle. Moreover, other sensors, such as UHF, NFC,GPS, Bluetooth, and temperature sensors, could be used in place of or inaddition to the RFID components in the RFID tag 30.

FIG. 2 illustrates an enlarged view of the RFID tag 30 in the outersurface 22 of the column 20. The column The RFID tag 30 includes anantenna 32 capable of communicating with a remote device 31, such as aRFID tag reader, through radio wave communication. The RFID tag 30transmits information about the pallet 10, the goods stored on thepallet 10, or the origin/destination of the goods stored on the pallet10 to the remote device 31. In the illustrated non-limiting example, theantenna 32 follows an elongated serpentine pattern such that the RFIDtag 30 has an elongated rectangular shape in the outer surface 22 of thecolumn 20.

The RFID tag 30 includes an outer construction 34 that is flush orrecessed with respect to the outer surface 22 of the column 20. Theouter construction 34 provides protection for the antenna 32. FIG. 3 isa cross-sectional view through the outer surface 22 and the outerconstruction 34 but not the antenna 32 along line 3-3 of FIG. 2. Theantenna 32 is located between the outer construction 34 and the column20. The outer construction 34 can be the same material as the injectionmolded portion of the pallet 10 or a dissimilar material. The outerconstruction 34 can also match the color of the column 20 or be of acontrasting color to the column 20. The outer construction 34 is alsosurrounded by a channel 36 that separates the outer construction 34 fromthe outer surface 22 of the column 20.

FIG. 4 illustrates a cross-sectional view of the RFID tag 30 along line4-4 of FIG. 2. In the illustrated non-limiting example, the RFID tag 30includes the outer construction 34 having a first construction surface33 and a second construction surface 35 on an opposite side of the outerconstruction 34 from the first construction surface 33. The firstconstruction surface 33 of the outer construction 34 faces the samedirection as the outer surface 22 of the column 20.

The antenna 32 is printed directly onto the second construction surface35 of the outer construction 34 such that the antenna 32 is spaced fromthe outer surface 22 of the column 20 by the thickness of the outerconstruction 34. The antenna 32 and a portion of the second constructionsurface 35 not covered by the antenna 32 would face into the column 20of the pallet 10 and be located adjacent and bond to the injectionmolded material of the pallet 10. In the illustrated non-limitingexample, a thickness dimension of the outer construction 34 is greaterthan a thickness dimension of the antenna 32 and the antenna 32 onlycovers a portion of the second construction surface 35.

FIG. 5 illustrates a cross-sectional view of another example RFID tag30A. The RFID tag 30A is similar to the RFID tag 30 except where notedbelow or shown in the Figures. The RFID tag 30A includes the outerconstruction 34, a first layer of adhesive 40, the antenna 32, and aninlay 38.

Instead of the antenna 32 being printed directed onto the outerconstruction 34 as with the RFID tag 30 shown in FIG. 4, the antenna 32in the RFID tag 30A is attached to the second construction surface 35 ofthe outer construction 34 with the first layer of adhesive 40 locatedbetween the antenna 32 and the outer construction 34.

Because the antenna 32 is not printed directly onto the outerconstruction 34 in the RFID tag 30A, the inlay 38 is used to providesupport for the antenna 32. The antenna 32 is attached to a first inlaysurface 37 on the inlay 38. The inlay 38 also includes a second inlaysurface 39 located on an opposite side of the inlay 38 from the firstinlay surface 37 and the antenna 32. The second inlay surface 39 facesinto the column 20 of the pallet 10 and would be located adjacent andbond to the injection molded material of the pallet 10 along with aportion of the second construction surface 35 of the outer construction34.

In the illustrated non-limiting example, a thickness dimension of theouter construction 34 is greater than a thickness dimension of theantenna 32 and a thickness dimension of the inlay 38. The thicknessdimension of the inlay 38 is less than a thickness dimension of theouter construction 34 and greater than a thickness dimension of theantenna 32.

The inlay 38 can be made of the same material as the outer construction34 or of a dissimilar material from the outer construction 34. When theinlay 38 is made of a similar material as the outer construction 34, theinlay 38 will act as a heat shield during molding of the pallet 10 andreduce the amount of blistering that appears on the first constructionsurface 33 that can result from molding.

FIG. 6 illustrates a cross-sectional view of yet another non-limitingexample RFID tag 30B. The RFID tag 30B is similar to the RFID tags 30,30A except where noted below or shown in the Figures. The RFID tag 30Bincludes the outer construction 34, the first layer of adhesive 40, theantenna 32, the inlay 38, a second layer of adhesive 44, and an innerconstruction 42.

Instead of the inner most layer of the RFID tag 30B being the inlay 38as shown with the RFID tag 30A in FIG. 5, the RFID tag 30B includes thesecond layer of adhesive 44 and the inner construction 42 located inwardfrom the second inlay surface 39. The inner construction 42 includes afirst inner construction surface 41 and a second inner constructionsurface 43 located on an opposite side of the inner construction 42 fromthe first inner construction surface 41. The second layer of adhesive 44contacts the second inlay surface 39 and the first inner constructionsurface 41 to fix the inlay 38 relative to the inner construction 42.

In the non-limiting illustrated example, dimensions of the first andsecond inner construction surfaces 41, 43 are equal to or greater thandimensions of the first and second inlay surfaces 37, 39. Additionally,the dimensions of the first and second inner construction surfaces 41,43 are less than dimensions of the first and second constructionsurfaces 33, 35. As described above in relation to the inlay 38 in theRFID tag 30A, the inner construction 42 will also further act as a heatshield during molding of the pallet 10 and reduce the amount ofblistering that appears on the first construction surface 33 that canresult from molding.

In the illustrated non-limiting example, a thickness dimension of theouter construction 34 is greater than a thickness dimension of theantenna 32 and a thickness dimension of the inlay 38. The thicknessdimension of the inlay 38 is less than a thickness dimension of theouter construction 34 and greater than a thickness dimension of theantenna 32. A thickness dimension of the inner construction 42 isgreater than the thickness dimension of the inlay 38 and less than orequal to the thickness dimension of the outer construction 34.

In order to ensure that the RFID tag 30 remains in a desired orientationwhile material is injected into the mold to form the pallet 10 or anyother injection molded product, a unique mold confirmation is utilized.FIG. 7 illustrates a cross-sectional view of the mold and RFID tag 30.The unique molding configuration incorporates a combination of a wall ordam 62 in a mold surface and vacuum lines 52 and/or pins 54 as shown inFIGS. 7-9. A heat source 57 can also be used to warm the RFID tag 30 toencourage bonding with the injected material.

FIG. 7 illustrates a cross-sectional view of a pallet mold through theRFID tag 30. The mold includes an outer portion 56 and an inner portion58. The outer portion 56 includes an inner surface 60 that forms theouter surface 22 of the column 20. The RFID tag 30 is also locatedadjacent the inner surface 60 of the outer portion 56 of the mold.

The inner surface 60 of the mold also includes the wall 62 thatsurrounds the RFID tag 30. The height of the wall 62 is greater than athickness of the entire RFID tag 30. In the illustrated embodiment, thewall 62 surrounds a portion of the inner surface 60 to define a suctionsurface 64 dimensioned to be larger than the first construction surface33 of the outer construction 34, which is the portion of the RFID tag 30that is in contact with the inner surface 60.

The vacuum lines 52 are in fluid communication with the suction surface64 to generate a suction force to hold the RFID tag 30 to the innersurface 60. The pins 54 are extendable across the mold to engage aninner surface of the RFID tag 30 to further maintain the RFID tag 30 inplace during the initial stages of the molding process. Althoughmultiple suction lines 52 are shown in the illustrated non-limitingembodiment, only a single suction line could be used. The pins 54 areremoved during the injection molding process to prevent the formation ofpassageways extending through the wall of the column 20 an inner side ofthe RFID tag 30.

In one example, the suction surface 64 is larger than the outerconstruction 34 on RFID tag 30 to allow material injected into the moldto fill a space between a perimeter of the RFID tag 30 and the wall 62.In another example, a perimeter of the outer construction 34 fitstightly against the wall 62 such that injected material will not reachthe suction surface 64.

The wall 62 protects to the RFID tag 30 during the injection moldingprocess to prevent the RFID tag 30 from moving or shifting during theinjection molding process. Arrows 66 indicate possible flow directionsfor the injected material entering the mold and passing over the RFIDtag 30. When the injected material travels over the wall 62, the wall 62prevents the injected material from moving the RFID tag 30 by disruptingthe generally linear flow of the injected material and creatingturbulent flow fields as indicated by arrows 68 adjacent the wall 62 andthe RFID tag 30.

FIGS. 8 and 9 illustrate a portion of the outer portion 56 and the innerportion 58 of the mold on opposite sides the RFID tag 30 that engage theRFID tag 30 with only the suction surface 64 shown on the inner surface60. The vacuum lines 52 are in fluid communication with the suctionsurface 64 to provide a negative pressure through a suction force fromthe external source 55 (FIG. 5) to secure the first construction surface33 of the outer construction 34 of the RFID tag 30 against the suctionsurface 64.

The pins 54 retractably extend through the inner portion 58 of the moldto engage the inner surface of the RFID tag 30 to further secure theRFID tag 30 against the suction surface 64. The pins 54 retract once apredetermined amount of material has been injected into the mold toprevent the formation of passageways through the columns 20 to the RFIDtag 30. Alternatively, the pins 54 are extended during the high speedinjection phase and retract during the slow speed injection phase.

FIG. 10 illustrates a portion of an automation system 100 used forplacing the RFID tag 30 against the suction surface 64 within the mold.The automation system 100 engages the RFID tag 30 with a suction device102. The suction device 102 includes a suction head 104 for directlycontacting and manipulating the RFID tag 30 and a suction line 106 influid communication with a suction source 108. The suction device 102transports the RFID tag 30 past a static charger 110 having a staticcharging head 112, which applies a static charge to the RFID tag 30 toassist in securing the RFID tag 30 against the suction surface 64 asdiscussed below.

The suction device 102 then places the RFID tag 30 against the suctionsurface 64 of the outer portion 56 of the mold. A leveling member 114 ofthe automation system 100 includes soft contacts 116 connected to anextendable arm 118. The extendable arm 118 of the leveling member 114extends past the suction device 102 to engage an inner surface of theRFID tag 30 that extends outward past the suction head 104. Because aportion of the RFID tag 30 extends past the suction head 104 in theillustrated example, the RFID tag 30 could curl away from the suctionsurface 64 and extend into the injection flow. To prevent this fromhappening, the leveling member 114 engages the inner surface of the RFIDtag 30 and presses the RFID tag 30 against the suction surface 64. Thestatic charge on the RFID tag 30 from the static charger 110 alsoprevents the RFID tag 30 from curling when placed against the suctionsurface 64.

FIG. 12 illustrates the inner portion 58 and RFID tag 30 with anotherexample outer portion 56A. The outer portion 56A is similar to the outerportion 56 except were described below or shown in the Figures.

Vacuum lines 52A are in fluid communication with a vacuum channel 70A ina suction surface 64A to provide a negative pressure through a suctionforce from the external source 55 (FIG. 7) to secure the firstconstruction surface 33 of the outer construction 34 of the RFID tag 30against the suction surface 64A. In the illustrated non-limitingexample, the vacuum channel 70A is recessed into the suction surface 64Aand includes a rectangular shape corresponding to the shape of the RFIDtag 30.

FIG. 13 illustrates the inner portion 58 and RFID tag 30 with yetanother example outer portion 56B. The outer portion 56B of the mold issimilar to the outer portion 56 except were described below or shown inthe Figures.

Vacuum lines 52B are in fluid communication with a porous material 72Bin a suction surface 64B to provide a negative pressure through asuction force from the external source 55 (FIG. 7) to secure the firstconstruction surface 33 of the outer construction 34 of the RFID tag 30against the suction surface 64A. Because the porous material 72B coversa larger area of the suction surface 64B, the RFID tag 30 can be securedwith greater force. Additionally, the large surface area of the porousmaterial 72B allows the RFID tag 30 to be placed against the suctionsurface 64B with less accuracy because the RFID tag 30 can establish asufficient seal by overlapping with a smaller portion of the porousmaterial 72B.

FIG. 14 illustrates another example RFID tag 30A similar to the RFID tag30 except where described below or shown in the Figures. The outerconstruction 34A includes an identifier 74, such as a bar code and/oralpha numeric characters, to provide a visual indication regardingorigin, destination, and/or contents stored on the pallet 10. Theidentifier 74 can be formed into a surface of the outer construction 34Aor attached with a sticker.

FIG. 15 illustrates a further example outer portion 56C that engages asensor 63C (FIG. 16), such as RFID, UHF, NFC, GPS, Bluetooth, ortemperature sensor. The sensor 63C is covered in a thin wall of plasticto protect the electronics within. The outer portion 56C does not relyon suction as described with the suction surfaces 64 described above.

The outer portion 56C includes a recessed surface 65C facing into acavity defined by the mold. The recessed surface 65C corresponds inshape to the sensor 63C. A first plurality of side supporting ribs 69Cposition the sensor 63C a proper distance from the recessed surface 65Cto allow injected material to fill the space defined by the recessedsurface 65C and a side surface of the sensor 63C.

A second plurality of ribs 71C include ledges 73C that position thesensor 63C a proper distance from to an upper and lower edge of therecessed surface 65C. Although the horizontal and vertical aligningfunction are performed separately by the first and second plurality ofribs 69C and 71C, respectively, the horizontal and vertical alignmentfunction of these ribs 69C and 71C could be combined into a single rib.Additionally, the first and second plurality of ribs could be arrangedin an alternating configuration or in groups of at least two similarribs adjacent to each other. Moreover, the recessed surface 65C and thefirst and second plurality of ribs 69C and 71C could be located in theinner portion 58 of the mold.

As shown in FIGS. 17 and 18, the sensor 63C is at least partiallysuspended in the column 20 of the pallet 10. The outer surface 22 of thepallet 10 also includes a plurality of slots 74 that correspond to thefirst and second plurality of ribs 69C and 71C. The sensor 63C isvisible through the slots 74.

Although the different non-limiting embodiments are illustrated ashaving specific components, the embodiments of this disclosure are notlimited to those particular combinations. It is possible to use some ofthe components or features from any of the non-limiting embodiments incombination with features or components from any of the othernon-limiting embodiments.

It should be understood that like reference numerals identifycorresponding or similar elements throughout the several drawings. Itshould also be understood that although a particular componentarrangement is disclosed and illustrated in these exemplary embodiments,other arrangements could also benefit from the teachings of thisdisclosure.

The foregoing description shall be interpreted as illustrative and notin any limiting sense. A worker of ordinary skill in the art wouldunderstand that certain modifications could come within the scope ofthis disclosure. For these reasons, the following claim should bestudied to determine the true scope and content of this disclosure.

What is claimed is:
 1. A method of forming an injection molded componentcomprising the steps of: locating a sensor against a first surface of amold, wherein an edge of the sensor is surrounded by a wall extendingfrom the first surface of the mold; and injecting an injectable materialinto the mold such that the injectable material travels over an innersurface of the sensor.
 2. The method of claim 1, wherein the sensor isattached to a construction and the construction contacts the firstsurface of the mold.
 3. The method of claim 2, including heating themold in a region of the sensor to adhere the construction to theinjectable material.
 4. The method of claim 1, wherein the wall isspaced inward from a perimeter of the first surface of the mold.
 5. Themethod of claim 4, wherein the wall completely surrounds the sensor. 6.The method of claim 4, wherein the sensor includes a UHF sensor.
 7. Themethod of claim 4, wherein the sensor includes a NFC sensor.
 8. Themethod of claim 4, wherein the sensor includes a GPS sensor.
 9. Themethod of claim 4, wherein the sensor includes a Bluetooth sensor. 10.The method of claim 4, wherein the sensor is a temperature sensor. 11.The method of claim 4, including shielding an edge of the sensor fromthe injectable material with the wall.
 12. The method of claim 11,including extending pins across a mold cavity to engage an inner surfaceof the sensor.
 13. The method of claim 4, including creating negativepressure with a vacuum line in fluid communication with the firstsurface to adhere the sensor to the first surface.
 14. The method ofclaim 4, including statically charging the sensor to adhere the sensorto the first surface.
 15. The method of claim 14, including contactingan inner side of the sensor with an extendable arm to increase contactbetween the sensor and the first surface of the mold.
 16. The method ofclaim 1, wherein the sensor includes a construction having an outersurface that forms a portion of an outer surface of the injection moldedcomponent.
 17. The method of claim 16, wherein the sensor includes anantenna having an inner surface and an outer surface and the outersurface of the antenna is attached to an inner surface of theconstruction with an adhesive and an inner surface of the antenna isattached to an inlay and the inlay is attached to a second constructionwith an adhesive and the second construction includes a smaller surfacearea relative to the construction.
 18. A method of forming an injectionmolded component comprising the steps of: locating a sensor against afirst surface of a mold, wherein an edge of the sensor is surrounded bya wall extending from the first surface of the mold; injecting aninjectable material into the mold such that the injectable materialtravels over an inner surface of the sensor; and shielding an edge ofthe sensor from the injectable material with the wall.
 19. The method ofclaim 18, including extending pins across a mold cavity to engage aninner surface of the sensor.
 20. A method of forming an injection moldedcomponent comprising the steps of: locating a sensor against a firstsurface of a mold, wherein an edge of the sensor is surrounded by a wallextending from the first surface of the mold; injecting an injectablematerial into the mold such that the injectable material travels over aninner surface of the sensor; and including creating negative pressurewith a vacuum line in fluid communication with the first surface toadhere the sensor to the first surface.
 21. A method of forming aninjection molded component comprising the steps of: locating a sensoragainst a first surface of a mold, wherein an edge of the sensor issurrounded by a wall extending from the first surface of the mold;injecting an injectable material into the mold such that the injectablematerial travels over an inner surface of the sensor; and staticallycharging the sensor to adhere the sensor to the first surface.
 22. Themethod of claim 21, including contacting an inner side of the sensorwith an extendable arm to increase contact between the sensor and thefirst surface of the mold.